Role of FSP in Surface Engineering

Abstract

Friction stir processing: Nowadays, much more attention toward surface modification techniques impart enhanced surface properties without altering the properties of the substrate material. The field of surface engineering encompasses thermal spray techniques, namely plasma spraying, flame spraying, and many others widely used for surface modification applications in the past. One major limitation of the thermal spray process is the change of phase at higher temperatures interacting with intense heat, thereby deteriorating the coating properties. Friction sir processing (FSP) is emerging as a suitable method to eliminate the drawback associated with thermal spraying. In FSP, friction plays a vital role in generating appropriate heat at the tool-workpiece interface, causing the material to soften to join due to severe plastic deformation. FSP and its variations are hence solid-state by nature. FSP modifies the surface integrity such as toughness, ductility, wear, and corrosion resistance without altering the qualities of the underlying material. Recent advancements encompass the fabrication of surface alloys and metal matrix composites by inserting the reinforcement particles in order to change the material’s surface properties by employing the FSP technique. As a result, FSP plays a significant role in surface engineering as a modification technique. This chapter summarizes the fundamental of friction stir processing along with the process parameters that affect the surface integrity (wear and corrosion). Further, their role in surface engineering as a modification technique is also discussed. In the end, the inappropriate parameters that affect the surface modification technique have been assessed. © 2024 by John Wiley & Sons, Inc. All rights reserved.